Instruction Manual. ThinkTop DeviceNet TM VDC ESE00355-EN The Top is identified by 4 fastening screws. Original manual TD800100_3

Transcription

1 Instruction Manual ThinkTop DeviceNet TM 25 VDC TD80000_3 The Top is identified by 4 fastening screws ESE00355EN Original manual

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3 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice. EC Declaration of Conformity Safety Important information Warning signs Safety precautions General information DeviceNet TM in generel Technical specifications ThinkTop DeviceNet TM features Installation Installation on air actuators Installation on Series 700 valves Air connections Electrical connection, internal Setup diagram ThinkTop setup utilising IR keypad ThinkTop setup utilising local I and II keys ThinkTop quick setup guide Fault finding Fault finding and LEDs Maintenance Dismantling of ThinkTop Assembly of ThinkTop Dismantling and assembly of Series 700 valves Part list and Service Kits Drawings for ThinkTop DeviceNet 25 VDC ThinkTop DeviceNet 25 VDC Drawings for ThinkTop Series 700 Valves ThinkTop Series 700 Valves

4 EC Declaration of Conformity The designating company Alfa Laval Company Name Albuen 3, DK6000 Kolding, Denmark Address Phone No. hereby declare that Top Unit for Valve Control & Indication ThinkTop DeviceNet TM Denomination Type Year is in conformity with the following directives with amendments: Low Voltage Directive (LVD) 2006/95/EF EMC Directive 2004/08/EF ROHS Directive 2002/95/EEC Manager, Product Centres, Compact Heat Exchangers & Fluid Handling Title Bjarne Søndergaard Name Alfa Laval Kolding Company Signature Designation 4

5 2 Safety 2. Important information Always read the manual before using the top unit! WARNING Indicates that special procedures must be followed to avoid serious personal injury. CAUTION Indicates that special procedures must be followed to avoid damage to the ThinkTop. NOTE Indicates important information to simplify or clarify procedures. 2.2 Warning signs General warning: Dangerous electrical voltage: Caustic agents: 5

6 2 Safety 2.3 Safety precautions Installation Always read the technical data thoroughly. Never install the ThinkTop before valve or relay is in a safe position. If welding close to the ThinkTop: Always earth close to the welding area. Disconnect the ThinkTop. Always have the ThinkTop electrically connected by authorized personnel. Maintenance Always read the technical data thoroughly. Always fit the seals between valve and ThinkTop correctly. Never service the ThinkTop before valve or relay is in a safe position. Never service the ThinkTop with valve/actuator under pressure. Never clean the ThinkTop with high pressure cleaning equipment. Never use cleaning agents when cleaning the ThinkTop. Check with cleaning agent supplier. 6

7 3 General information 3. DeviceNet TM in generel DeviceNet TM is a lowcost communication link to connect industrial devices (such as limit switches, photoelectrical sensors, valve manifolds, motor starters, process sensors, bar cod readers, variable frequency drives, panel display and operator interfaces) to a network and eliminate expensive handwiring. The direct connectivity provides improved communication between devices as well as important devicelevel diagnostics not easily accessible or available through hardwires I/O interfaces. DeviceNet TM is a simple networking solution that reduces costs as well as time to wire and install industrial automation devices, while providing interchangeabillity of similar components from multiple vendors. DeviceNet TM is an open network standard. DeviceNet TM features and functionality Network size Network length Data Packets Bus Topology Bus Addressing System Features Up to 63 nodes Selectable endtoend network distance varies with speed Baud Rate Distance 25 Kbps 500 (,640 ft) 250 Kbps 250 (820 ft) 500 Kbps 00 (328 ft) 08 bytes Linear (trunk line/drop line); power and signal on the same network cable PeertoPeer with MultiCast (onetomany); MultiMaster and Master/Slave special case; polled or changeofstate (exceptionbased) Removal and replacement of devices from the network under power The basic trunk line/drop line topology provides separate twisted pair busses for both signal and power distribution. Thick or thin cable can be used for either trunk lines or drop lines. Endtoend network distance varies with data rate and cable size. Data Rates 25 Kbps 250 Kbps 500 Kbps Thick Trunk Length 500 m (,640 ft) 250 m (820 ft) 00 m (328 ft) Thick Trunk Length 00 m (328 ft) 00 m (328 ft) 00 m (328 ft) Maximum Drop Length 6m(20ft) 6m(20ft) 6m(20ft) Cumulative Drop Length 56 m (52 ft) 78 m (256 ft) 39 m (28 ft) The endtoend network distance varies with data rate and cable thickness. DeviceNet TM requires a terminating resistor to be installed at each end of the trunk: 2 Ohm % metal film /4 Watt Terminating resistors should not be installed at the end of a drop line, only at the two ends of the trunk line. For further information please see the DeviceNet TM Standard. 7

8 3 General information DeviceNet TM Features Device Type Generic Master/scanner N Explicit peer to peer messaging N I/O Slave messaging I/O peer to peer messaging N Bit strobe N Configuration consistency value N Polling Y Faulted node recovery N Cyclic N Baud rates 25K, 250K, 500K 25K, 250K, 500K Y Configuration method EDS The endtoend network distance varies with data rate and cable thickness. Special DeviceNet TM functions Class 00 Attributes Setup commands Time to maintenance Opencount Configurator Laststroketraveltime Closedcount Alarmsetup Last stroke travel length (mm) Time of last maintenance TimeTotal Current position [mm] (0 80 mm) Time Closed Activation s solenoid no. TimeOpen Activation s solenoid no. 2 Activation s solenoid no. 3 See also section 3..4 ThinkTop DeviceNet TM Attribute List DeviceNet TM interface Baud rates: 25k, 250K and 500k. Polling and change of state (COS) I/O slave messaging. Poll: 7 or 2 bytes (optional). 2 bytes = Input/outputs and alarms (class 4). 7 bytes = Input/outputs alarms and class 00/attributes. 7 bytes is standard. Changing from 7 bytes to 2 bytes: remove jumper (#2 and #3). A power recycle is necessary when changing byte sizes. COS: 2bytes,7bytesisnotsupported. Node address Range: Default slave address: 63. Power Supply The power supply to the complete unit is taken from the DeviceNet. Supply voltage: 25 V DC, as specified for the DeviceNet. Supply current: Max. 45 ma (for sensor unit alone) (excluding current to the solenoids and the external proximity switches). Electrical connection: Direct cable gland entry (hard wired). PG (ø4 ø0 mm). PG7 (ø3 ø6.5 mm) option, external sensor. 8

9 4 Technical specifications 4. ThinkTop DeviceNet TM features No Touch sensor system TD Sensor unit 2. PLC, feedback 3. Sensor board 4. PLC interface board 5. IR Remote control 6. IR Rx 7. Serial link 8. LEDs V 0. Terminals. Terminals 2. ASI + 3. ASI 4. Bus Connection 5. Internal connections 6. Solenoid signals (DC) 7. Solenoid common 8. External seatlift (PNP) 9. Supply sensors 20. External connections Type: Alfa Laval No Touch System. For wire connections: See 5.4 Electrical connection, internal. Features Tolerance programmes. Self adjustment programme (SRC/ARC valves only). Builtin maintenance monitor. Setup by internal push buttons or remote control (IR Keypad). Setup and local fault supervision. Setup saved at power shutdown. Visual LED Indicator lights. Sensor System Unique No Touch sensor system without any mechanical sensor adjustments. A magnet (indication pin) is mounted on the valve stem and the magnetic field (axial) is detected by sensor chips inside the sensor board. The measuring angle from each chip is used to locate the current position of the valve stem with an accuracy of ± 0.mm. Note that the distance to the indication pin can be 5 mm ± 3 mm. Feedback signals Input signals (produced by the sensor unit) transmitted over the DeviceNet TM class4. Five feedback signals: Closed valve, open valve, seatlift, seatlift 2 and status. The status signal is used for five purposes: To indicate that a setup is in progress (LED D). To indicate an error condition (LED D), (flashing = software error), (steady = hardware error). To indicate that maintenance is required (LED F). To indicate if there is a conflict in the self adjustment programme (LED F). To indicate if no communication exists between ThinkTop and PLC (LED D, steady). Tolerance programme Individual programme according to valve types. Type 0: Type : Type 2: Type 3: Type 4: Type 5:...Bypass valve type / keep present valve type....src/arcandseries 700valves, onlywhenselfadjustmentisenablednotrecommended....lkb (LKLAT)....Unique Mixproof, SMPSC SpillageFree, and SRCPV....SMPSC, SMPTO, SMPBC, SMPBCA, SBV, SRC, ARC, Unique SSV, Unique SSV Aseptic, UniqueTO and Series 700 valves....all Parameters Set To Default (also valid for MH valve and SMPEC (seatlift indication not possible for SMPEC)). Preset and reset values: Tolerance programme No./Type 5 (± 5mm) and all functions are disabled. Note! Important to select the right tolerance programme in order to ensure optimum controlled closeness of valves. 9

10 4 Technical specifications Self Adjustment (SRC/ARC valves only) The self adjustment feature is an exceptional aspect of the ThinkTop design. A programme can be activated to allow an adjustment of the tolerance band if the seals in the valve are being compressed or are worn. When the tolerance band of the unit has been adjusted 0.3 mm, an alert warning will appear in the form of a status signal and a flashing maintenance LED. After 0.5 mm adjustment an alarm warning appears: Loss of feedback signal, status signal and steady maintenance light indicating a replacement of the seal. Builtin Maintenance Monitor The unit can be preset to indicate when the time for maintenance of the valve has been reached. A status signal and flashing maintenance LED can be programmed to return after 3, 6, 9 or 2 months or more. Technical specifications Sensor system Sensor accuracy:... ± 0. mm. Distance to indication pin:...5 ± 3 mm. Stroke length: mm. Electrical connection: Direct main cable gland entry (hard wired) PG (ø4 ø0 mm). Direct external/sensor cable gland entry PG7 (ø3 ø6.5 mm) option, external sensor. Terminals The terminal row of the sensor unit is equipped with screw terminals for both internal as well as external cables and wires. The terminals are suitable for wires up to 0.75 mm 2 (AWG 9). External sensors The external sensors are used for seatlift supervision when seatlift can not be internally detected. The sensors get their supply voltage from the terminal row. The output signals from the sensors are connected to two inputs on the terminal row on the internal sensor unit. If the actual setup is set for internal seatlift, the corresponding external signal is not used, otherwise the external signal logically controls the corresponding feedback to the PLC (Programmable Logic Controller). Note! If using external sensor, the sensor must be active/activated when performing a setup routine of the control head. Supply voltage:...as specified for the ASInterface (typical 30VDC) Supply current:...max. 5 ma per sensor. Type of sensor:...vdc, only 3wire sensor, PNP. Cable length:...max. 3 m. Alarm mask Output signals received from the DeviceNetTM (consumed by the sensor unit). Fourbit mask to disable the alarm functions for the states closed, open, seatlift and seatlift 2 respectively. See also section 3..4 ThinkTop DeviceNetTM Attribute List. ThinkTop Visual Indications LED Indications LED B LED B Open valve (Yellow) O IRReceiver LED D LED D Setup/Internal fault (Red) LED C LED C Seatlift /2 (Yellow) LED E LED E Solenoid valves (Green) LED F LED F Maintenance (Orange) LED A LED A Closed valve (Yellow) 0

11 4 Technical specifications Note: If the programmer wishes to detect a physical closed valve position in an Open Valve sensor position, then there is no longer any consistence between the sensor valve detection position and the visual indications of the ThinkTop. Technical specifications solenoid valves Solenoid signals Output signals received from the DeviceNet TM (consumed by the sensor unit) class 4. Three bits to control the solenoid drives located in the sensor unit. Internal connections (solenoids) The solenoid drivers are reducing the solenoid power by PWM after activation. The number of solenoids actually mounted in the control head could be 0 3. Technical specifications Up to 3 solenoid valves in each unit. Type 3/2 or 5/2 valve (only possible with one 5/2 valve). Air supply kpa (39 bar). Filtered air, max. particles or dirt 5 55 mg/m 3. Max. flow 80 l/min. Max. oil content mg/m 3. Max. water content 0.88 g/m 3 20 o C compressed air. Throughput ø2.5 mm. Air restriction (throttle function) air inlet/outlet. Yes. Manual hold override. Yes. External air tube connection ø6 mm or /4 (specify when ordering). Silencer/filter Connection possible via ø6 mm or /4". (Filter recommended in tropical regions). Solenoids drive Solenoid valve 8 VDC. O/P Valtage 8 VDC +/ 5% Power consumption 0.75W Max. Current consumption (per solenoid) 30mA Max. PWM Pullin pulse length50ms Max. 50ms Max. PWM duty cycle 40% +/ 0% PWM frequency 2kHz+/0% PWM = Pulse width modulated *) Note! Filter recommended in tropical regions. Technical specifications aux. outputs Three aux. outputs can be used for external devices. The drivers are always NPN outputs and PWM mode is not possible. The number of aux. outputs for activation of external devices can be 03. Clarification: All 3 outputs can be activated at the same time but if solenoid is in use, aux. can not be used! If solenoid and 2 are in use, aux. and 2 can not be used! If solenoid, 2 and 3 are in use, no aux. can be used! A mix of solenoid and aux. outputs is possible. Output: Output voltage: Load current: NPN (sinking). 24 VDC ± 5%. Network power connection! User must ensure 24 VDC on the network (at the top) when these outputs are used. Max 75 ma. As these outputs drive constant current, using several nodes in this mode will reduce the number of nodes supported by a typical 8A network supply. The user must ensure that total network current consumption is less than the supply rating. ThinkTop, EDS file Please see web address for further information and for downloading the EDS file or contact your Alfa Laval company.

12 4 Technical specifications ThinkTop DeviceNet TM attribute list Path Name Attributes R/W/CS data type Release DNET 4.6 Class Inst dec. hex. poll Valve value 4 3 R Byte Valve command R/W Byte Alarm status R Byte Alarm mask R/W Byte Extended status # Extended Status #2 Setup command Configuration Alarm # Setup Alarm #2 Setup Alarm #3 Setup Alarm #4 Setup Alarm #5 Setup Alarm #6 Setup Current position Time TOTAL Time CLOSED Time OPEN Time to Maint. Last stroke Time Last Stroke Length Coil Count # Coil Count #2 Coil Count #3 OPEN Count CLOSED Count Time of Last Maint E 6F 79 7A 7B 7C 7D 7E A 8B 8C 8D 8E A 0B A E F A R R R/W R R/W R/W R/W R/W R/W R/W R R R R R R R R R R R R R Byte Byte Byte Byte Byte Byte Byte Byte Byte Byte UINT UINT UINT UINT UINT UINT UINT ULINT ULINT ULINT ULINT ULINT UINT Raw data len LSB sec sec sec sec sec sec m 2.38 hrs hrs hrs hrs. 0.3 sec mm counts counts sounts counts counts 2.38 hrs. 2

13 4 Technical specifications ThinkTop DeviceNet TM attribute list Name Eng. Units Conv. Bit maps/data mult. divisor units byte byte 2 byte 3 byte 4 Release DNET 4.6 Valve value Valve command Alarm status Alarm mask Extended status # Extended Status #2 Setup command Configuration Alarm # Setup Alarm #2 Setup Alarm #3 Setup Alarm #4 Setup Alarm #5 Setup Alarm #6 Setup Current position Time TOTAL Time CLOSED Time OPEN Time to Maint. Last stroke Time Last Stroke Length Coil Count # Coil Count #2 Coil Count #3 OPEN Count CLOSED Count Time of Last Maint ,000 0,000 0,000 0,000 0, ,000 0,000 mm days days days days sec. mm days PLC_image Solenoids,2&3 Alarm_Status Alarm_Mask Error_Byte Alarm_Status ASI_Data(4...7) M_Config End condition End condition End condition End condition End condition End condition LSB LSB LSB LSB LSB LSB LSB LSB LSB LSB LSB LSB LSB Travelstatus Travel Mask PLC_Image Travel_Status DConfig Time Time Time Time Time Time MSB MSB MSB MSB MSB MSB MSB mid byte mid byte mid byte mid byte mid byte MSB LED_Image Adjust_Status MSB MSB MSB MSB MSB

14 4 Technical specifications ThinkTop DeviceNet TM bit mappings PLC_Image (feedbacks) Travel in progress Alarm timer expired x Maint. SL2 SL OPEN CLOSED LED_Image x x CLOSED Maint. Coil Seat Lift Setup OPEN Timeout Multiple Position Check on last Button II Button I Tx/Rx Bus Error_Byte coil Over Sum command failure failure failure Offline request Range Error Solenoid,2 &3 x x x x Coil #3 Coil #2 Coil # x CLOSED CLOSED OPEN Adjust_Status x x Alert Alarm x x x Alarm Travel_Status Timeout Alarm_Status Alarm Setup (..6) End condition: Time: LSB=0.524 sec. Travel in Progress Timer Running x x x x x x x On last command Alarm Mask x x Travel Mask x x Alarm #6 active Alarm #5 active Alarm #4 active Alarm #3 active Alarm #2 active Alarm #2 active Steady x x x SL2 SL OPEn CLOSED ~ 67, s ~ 33,5 s ~ 6,8 s ~ 8,4 s ~ 4,2 s ~ 2, s ~,0 s ~ 0,5 s Coil #3 deenergize enabled Coil #3 deenergize disabled Coil #2 deenergize enabled Coil #3 deenergize disabled Coil # deenergize enabled Coil #3 deenergize disabledis Coil #3 energize enabled Coil #3 energize disabled Coil #2 energize enabled Coil #3 energize disabled Coil # energize enabled Coil #3 energize disabled 4

15 4 Technical specifications ThinkTop DeviceNet Poll and COS command structures Poll Request Message format bit byte x x x x Coil # Coil #3 Coil #2 deenergize deenergize deenergize x x x 2 Write Attrib. Flag Alarm #6 enable coil #3 enrgize Alarm #5 enable coil #2 enrgize Alarm #4 enable coil # enrgize Requested index for Class #00 attribute. Note: The index is 0relative based on attribute ID #00 3 AttributeDataByte0LSB 4 AttributeDataByte 5 AttributeDataByte2 6 AttributeDataByte3MSB Alarm #3 enable coil #3 enrgize Alarm #2 enable coil #2 enrgize Alarm # enable coil # enrgize Poll Response Message Format bit byte Travel in Timer MAINT. Seat #2 Seat # OPEN CLOSED Progress Expired x ERROR Status Status Status Status Timer Running Timer Expired Alarm #6 active Alarm #5 active Alarm #4 active Alarm #3 active Alarm #2 active Alarm # active 2 Data Note: The index is 0relative based on attribute ID #00 Flag Valid Requested index for Class #00 attribute. 3 AttributeDataByte0LSB 4 AttributeDataByte 5 AttributeDataByte2 6 AttributeDataByte3MSB Note! The 2 bytes Poll command structure is the same as the 7 bytes command with only bytes 0, used. 5

16 4 Technical specifications COS command structure COS Request Message By definition the COS and Poll Request Messages are identical. For a device configured for a 7 bytes Poll, the corresponding COS request will be: bit byte Coil #3 Coil #2 Coil # 0 x x x x x energize energize energize Alarm #6 Alarm #5 Alarm #4 Alarm #3 Alarm #2 enable enable enable enable enable x x coil #3 coil #2 coil # coil #3 coil #2 deenergize deenergize deenergize energize energize 2 Write Attrib. Flag Requested index for Class #00 attribute. Note: The index is 0relative based on attribute ID #00 3 AttributeDataByte0LSB 4 AttributeDataByte 5 AttributeDataByte2 6 AttributeDataByte3MSB Alarm # enable coil # enrergize For a device configured for a 2 bytes Poll, the corresponding COS request will be. bit byte Coil #3 Coil #2 Coil # 0 x x x x x energize energize energize Alarm #6 Alarm #65 Alarm #4 Alarm #3 Alarm #2 Alarm # enable enable enable enable enable enable x x coil #3 coil #2 coil # coil #3 coil #2 coil # deenergize deenergize deenergize energize energize energize COS Response Message: Only a 2 bytes message is supported and corresponds to the 2 byes Poll response message format. bit byte Travel in Timer MAINT. Seat #2 Seat # OPEN CLOSED Progress Expired x ERROR Status Status Status Status Timer Timer Alarm #6 Alarm #5 Alarm #4 Alarm #3 Alarm #2 Alarm # Running Expired active active active active active active Note! A 7 bytes COS response message is not supported. COS Trigger The COS message is triggered by any change in the Valve Value (feedbacks) corresponding to byte0 of the COS response message. 6

17 4 Technical specifications Typical power consumption Test conditions: One ThinkTop DeviceNet TM 25 VDC connected ti the network with input (on) and: No solenoids on supply voltage 25 VDC 20 ma solenoid active (PWM) supply voltage 25 VDC 28 ma 2 solenoid active (PWM) supply voltage 25 VDC 36 ma 3 solenoid active (PWM) supply voltage 25 VDC 44mA No solenoids on supply voltage VDC 34 ma solenoid active (PWM) supply voltage VDC 58 ma 2 solenoid active (PWM) supply voltage VDC 82 ma 3 solenoid active (PWM) supply voltage VDC 06 ma Note: If the Aux. Outputs are used instead of the solenoids for activation of external devicces, the consumption is depending on the load current (see Aux. Outputs ). Materials Plastic parts Nylon PA2 Steel parts Stainless steel AISI 304 and 36 Seals FPM (air fittings), EPDM rubber for SMPEC stem Gore Vent. membrane PBT palstic Micro environment demand specifications Temperature Working: 20 C to +85 C IEC 682/2 Storage: 40 C to +85 C IEC 682/2 Temperature change: 25 C to +70 C IEC 6824 Vibration 055Hz,0.7mm IEC Hz, 0g 3x30min,octave/min Drop test IEC Humidity Constant humidity: +40 C, 2 days, 93% R.H. IEC 6823 Cyclic humidity: +25 C/+55 C 2 cycles IEC (working) 93% R.H. Protection class IP66 and IP67 IEC 529 Input treshold Voltage/current: Type input requirements EN 632 EMC Directive 2004/08/EF EN , EN ASInterface Version 2.*) EN50295 Version 3.0 **) UL Approval 830 VAC/VDC, Class 2 input, 45 ma max. output UL 508E *) Max. 3 ThinkTop units on a single master/gateway. **) Max. 62 ThinkTop units on a single master/gateway. 7

18 5 Installation 5. Installation on air actuators Step Always read the technical data thoroughly. Always have the ThinkTop electrically connected by authorized personnel. Step 2. Fit the air fittings on actuator if not mounted. 2. Fit the activator stem (magnet) and tighten carefully with a spanner. SRC/ARC only Step 3. Place the ThinkTop on top of the actuator. 2. Make sure Xring is mounted. 85 Step 4. Ensure that the unit is correctly mounted by pressing down on top of the ThinkTop. 2. Tighten the two Allen screws carefully (.50 Nm). 3. Turn the actuator to have LEDs in a front view. 8

19 5 Installation Step 5 Fit the ø6 mm (/4 ) air tubes to ThinkTop. (see drawing Air connections page 22). Step 6 Fit the air tubes to the actuator (see drawing Air connections page 22). TD 8003 Step 7 Untighten the four screws and pull off cover of ThinkTop. TD Step 8. Install cable (if not present) through the cable gland. 2. Connect the ThinkTop electrically (see page 5.4 Electrical connection, internal). TD

20 5 Installation Step 9 Make sure the cable gland is completely tightened. TD Step 0 Set up the ThinkTop (see chapter 6 Setup diagram). NOTE! The unit can be set up with the cover installed by using the IR keypad. To energize the valve, use a separate air tube or be in radio contact with the control room. 20

21 5 Installation 5.2 Installation on Series 700 valves Step. Remove the cover by loosening the four cover screws. 2. Separate the adapter from the base by loosening the three recess screws on top of the base. Installation on air actuators: TD Step 2. Fit air fittings on actuator. 2. Position packing retainer in recess on actuator top. 3. Fit counter nut and indication pin (magnet) on actuator rod. Engage approx. ¼ thread. Tighten counter nut and indicator with two wrenches. Step 3. Place the two Orings in the grooves in the bottom of the adapter. Then place the adapter on the actuator top. The small Oring must be positioned over the air hole on the actuator. 2. Fasten the adapter with the four 5/6 Allen screws. Step 4 Mount the base on the adapter in the position needed (can be rotated 20 in both directions). Note that one of the screw towers on the adapter has a guide recess (see * on drawing). TD

22 5 Installation 5.3 Air connections A B K C D E J 2 F I 3 TD G H A. Air restriction (throttle function) air inlet/outlet B. Air out A C. Air exhaust D. Air out B (5/2 port solenoid valve only) E. Solenoid 3/2 or 5/2 F. 3/2 Solenoid valves only G. Air restriction (throttle function) air inlet/outlet H. Air in I. Air out 3 J. Air out 2 K. Manual hold override 22

23 5 Installation 5.4 Electrical connection, internal A Bus Connection C PWM Jumper**) B Internal connections to D Incoming signals from external sensors ****) solenoid 3 ***) E Supply to external sensors *) 6 ASI + N/C 7 ASI 2 N/C 8 N/C 3 N/C 9 N/C 4 N/C 0 N/C 5 N/C N/C 2 PWM Jumper **) Earth 3 PWM Jumper **) 20 Solenoid common brown 24 Seatlift upper *) 2 Solenoid, blue 25 Seatlift 2 lower *) 22 Solenoid 2, blue 26 Supply + *) 23 Solenoid 3, blue 27 Supply *) Table. Note! *) Terminals 24, 25, 26 and 27 can be used for external seat lift sensors as well as for any digital input. Always use an external PNP sensor. Two external signals can be connected, they are associated with feedback signal 3 (seat lift ) and 4 (seat lift 2). External sensor must always be a 830 VDC PNP 3 wire sensor. Connect () common on terminal 27, and (+) common on terminal 26. The signals from the external sensors are associated as follows: sensor signal on terminal 24 (seat lift ) associated with feedback 3 (seat lift ), and sensor signal on terminal 25 (seat lift 2) associated with feedback 4 (seat lift 2). **) Jumper present = PWM. See section 3..3 Technical specifications solenoid valves. ***) Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of solenoids actually mounted in the control head could be 0 3. The signals are taken directly from the terminal row. ****) If using external sensor, the sensor must be active/activated when performing a setup routine of the control head. 23

24 6 Setup diagram 6. ThinkTop setup utilising IR keypad General Flashing LED means no value set. Steady LED means value set as shown Default: Step 2, Factory set tolerance band +/ 5mm Step 38, disabled D LED: Active during setup: Flashing in step Steady in all other steps Or during operations, error condition: Steady showing hardware fault, indication pin out of range Flashing showing software fault Timeout: IR Keypad: A 60 sec. timeout is started as soon as any button(s) are released On timeout the setup is exited with no changes saved Remote distance 0300 mm to ThinkTop Symbols X PushkeyonIRkeypadwiththesamenumber Simple representation of LED indication: Yellow B IRReciver Red D Steady LED Yellow C Green E Orange F Yellow A Flashing LED General commands in each step (except step ): 0 Next step / skip step (In step 36 the program automatically moves to the next step when a position is stored) 5 Clear / disable step (In step 2 this resets the unit and set the step 28 to default) (The command is accepted when all unit LED s flash briefly) It is recommended to reset the unit before performing a setup Always check for correct signals after the setup 24

25 6 Setup diagram 0 0 Enter Setup Step B Save and Exit D Next C 2 Exit no change accepted step E F A 0 Step 2 Setup valve type B Default SRC/ARC LKB Unique SMPSC +/ 5mm Series 700 (LKLAT) Mixproof, SMPBC D (Only used SRCPV SMPTO Next C when self spillagefree SMPBCA Reset unit step E adjustment SMPSC SBV F feature is Unique SSV. 5 A required) SRC/ARC Series 700 Step 3 Set closed position B Default Position stored. 0 D Next C step E F A Activate the valve to the close position (Deenergized) auto Cleat position 5 0 Step 4 Set open position B Default Position stored Next D step C E F Activate the valve to the open position (Energized) auto Clear position 5 Step 5 Set upper seat lift. B Default Position stored 0 Next D Activate the valve to upper seat lift. When Clear step C position using an external sensor the sensor must be E 5 F active when is pushed auto A 0 Step 6 Set lower seat lift. B Default Position stored. Next Clear step D Activate the valve to lower seat lift. When position C E using an external sensor the sensor must be 5 F active when is pushed auto A 0 0 Step 7 Set self adjust (Recommended: Disabled) B Default Associated Associated Associated Next Disabled with with with step D closed/ closed open Disable C open position position function E position F A Step 8 Setup maintenance B Default 90 days 80 days 270 days 360 days Disabled Next D Disable step C function E F A 25

26 6 Setup diagram 6.2 ThinkTop setup utilising local I and II keys General Default is: Timeout: Step 2, tolerance is +/5mm Step 38, disabled A 60 sec. timeout is started as soon as any button(s) are released On timeout the setup is exited with no changes saved Flashing LED means no value set. Steady LED means value set as shown [D] LED: Active during setup: Flashing in step Steady in all other steps Or during operations, error condition: Steady showing hardware fault, indication pin out of range Flashing showing software fault General commands in each step (except step ): 5s Next step / skip step (In step 36 the program automatically moves to the next step when a position is stored) 5s Clear / disable step (In step 2 this resets the unit to default) (The command is accepted when all unlit LED s flash briefly) It is recommended to reset the unit before performing a setup Symbols 5s Push local key I 5s Push local key II 5s Hold key II for 5 sec Simple representation of LED indication: Yellow B IRReciver Red D Steady LED Yellow C Green E Orange F Yellow A Flashing LED 26

27 6 Setup diagram Enter Setup Step B 5s Save and Exit D Next C 5s Exit no change accepted step E F A Step 2 Setup valve type B Default SRC/ARC LKB Unique SMPSC +/ 5mm Series 700 (LKLAT) Mixproof, SMPBC D (Only used SRCPV SMPTO Next C when self spillagefree SMPBCA step E adjustment SMPSC SBV F feature is Unique SSV A required) SRC/ARC Next Series 700 step Step 3 Set closed position B Default Position stored D Next C step E F A Activate the valve to the closed position (Deenergized) auto Step 4 Set open position B Default Position stored Next D step C E F Activate the valve to the open position (Energized) auto Step 5 Set upper seat lift B Default Position stored Next D step C E F A Activate the valve to upper seat lift. When using an external sensor the sensor must be active when II is pushed auto Step 6 Set lower seat lift B Default Position stored D Next C step E F A Activate the valve to lower seat lift. When using an external sensor the sensor must be active when II is pushed auto Step 7 Set self adjust (Recommended: Disabled) B Default Associated Associated Associated Disabled with with with Next D closed/ closed open step C open position position E position F A Next step Step 8 Setup maintenance B Default 90 days 80 days 270 days 360 days +90 days Disabled (Up to Next D max. step C 8 years) E F A Next step 27

28 6 Setup diagram 6.3 ThinkTop quick setup guide Valve: Unique SSV, SRC/ARC type NC (selfadjustment disabled) Push: I and wait until red LED flashes Push: I Push: II hold for 5 sec (clear all stored parameters) Push: II (red + yellow LED) Push: II (red + yellow + green LED) Push: II (red+yellow+green+orangeled) Push: II (red+yellow+green+orange+yellowled) Push: Push: I II to approve valve down (closed) Push: Activate Valve opens II to approve (open) Push: I (no upper seatlift) Push: I (no lower seatlift) Push: I (no self adjustment) Push: I (no maintenance) Push: II Red LED flashes (save & exit by push) Setup done Valve: SRC/ARC type NO (selfadjustment enabled) Push: I and wait until red LED flashes Push: I Push: II hold for 5 sec (clear all stored parameters) Push: II (red + yellow LED) Push: I Activate Valve closes Push: II to approve valve closed Push: Deactivate Valve opens Push: II to approve valve is open Push: I (no upper seatlift) Push: I (no lower seatlift) Push: II = self adjustment Push: Push: I I (no maintenance) Push: II Red LED flashes (save & exit by push) Setup done Valve: LKB Valve (Butterfly) NC Push: I and wait until red LED flashes Push: I Push: II hold for 5 sec Push: II (red + yellow LED) Push: II (red + yellow + green LED) I Push: II to approve valve closed (indication stem up) Push: Activate LKB valve open position (indicationstem down) Push: II to approve valve is open Push: I (no upper seatlift) Push: I (no lower seatlift) Push: I (no self adjustment) Push: I (no maintenance) Push: II Red LED flashes (save & exit by push) Setup done 28

29 6 Setup diagram Valve: LKB Valve (Butterfly) NO Push: I and wait until red LED flashes Push: I Push: II hold for 5 sec (clear all stored parameters) Push: II (red + yellow LED) Push: II (red + yellow + green LED) Push: I Activate to approve valve closed (indication stem up) Push: II to approve valve closed Push: Deactivate LKB valveopen position (indicationstem up) Push: II to approve valve is open Push: I (no upper seatlift) Push: I (no lower seatlift) Push: I (no self adjustment) Push: I (no maintenance) Push: II Red LED flashes (save & exit by push) Setup done Valve: Unique mixproof Valve (with lower seatlift) Push: I and wait until red LED flashes Push: I Push: II hold for 5 sec (clear all stored parameters) Push: II (red + yellow LED) Push: II (red + yellow + green LED) Push: II (red+yellow+green+orangeled) I Push: II to approve valve closed Push: Activate Valve opens II to approve valve is open Push: Activate Lower seatlift active Push: II to approve Push: I (no self adjustment) Push: I (no maintenance) Push: II Red LED flashes (save & exit by push) Setup done 29

30 7 Fault finding 7. Fault finding and LEDs Below is stated the meaning of the LEDs indications for fault finding in connection with the operation of the ThinkTop. 7.. status LED (Red) Red flashing: Unit in setup mode or internal software fault. If internal software fault, reprogramme unit. Red Red steady: Unit in setup mode or internal hardware fault. If internal hardware fault, check if magnet is in range and check correct wiring. Red steady: No. communication between ThinkTop and the DeviceNet master, i.e. the bus is offline. If the Red LED is with random intervals and duration, it suggests that the bus is unstable, and the DeviceNet network should then be investigated. There are numerous issues that could lead to marginal operation of a network, bus load, voltage limits, impedance, termination, etc Maintenance time out Yellow B.Orange flashing: Time for maintenance has run out. The unit has been selfadjusted into a maintenance alert condition. Valve maintenance is strongly recommended. After maintenance: Disabling of maintenance/selfadjustment function is required before setting new position, however, it is strongly recommended to make a complete new setup after valve maintenance. Orange Yellow A 2.Orange steady, yellow flashing (A and/or B): The unit has been selfadjusted into a maintenance alarm condition and the feedback is lost (a minimum of seal left). Valve maintenance is required. After maintenance: Disabling of the selfadjustment function is required before setting new position, however, it is strongly recommended to make a complete new setup after valve maintenance. NOTE! The maintenance indicator lighting up, and an open or closed light flashing... = Note the following: Selfadjustment programme is only valid for SRC/ARC valves, do not use the programme for other valve types. Use tolerance/valve type. In conjunction with valve type changeover; 2, 22, 3 and 32, the open position must be defined as the upper sensor position (when the indication pin is in the highest position). A loose top, indication pin or sensor system can also generate the alert/alarm condition. Removing a ThinkTop with selfadjust activated, will immediately generate an alarm condition! If the ThinkTop has to be removed, not because of a valve maintenance issue, but for some other reasons, and you want to store the already adjusted data disable the selfadjust function before removing the ThinkTop and enable it again once the ThinkTop is back on the actuator. After valve maintenance a disabling of the selfadjustment function is required before setting a new position, however, it is strongly recommended to make a complete new setup (disable all functions in step 2 valve type and make a complete new setup). 30

31 7 Fault finding 7.2 LED indication during normal operation Yellow A Yellow steady: Position A (closed valve). Yellow B Yellow steady: Position B (open valve). Yellow C Yellow steady: Position C (Seat lift 2 or external sensors). Green Green steady: Solenoid valves energized. Note! During setup LED lights have different functions. 3

32 8 Maintenance Study the instructions carefully. Handle scrap correctly. Always keep spare Xrings in stock. 8. Dismantling of ThinkTop Step. Untighten the two Allen screws and remove the ThinkTop from the actuator. 2. Pull out Xring (9) andreplaceit. 85 Step 2. Untighten the four screws. 2. Pull off cover of ThinkTop. 3. Remove Xring (9) (grey). TD Step 3. Untighten screws. 2. Remove solenoid valves (up to three) and replace them with new ones. TD Step 4. To dismantle the adapter (the lower part of the ThinkTop) from base (the middle part), unscrew the three screws. 2. Turnthelowerpartalittleclockwiseandpull. 3. Replace adapter if necessary. 4. Remove the black Xring. Note: Turn banjo connection! TD

33 8 Maintenance Study the instructions carefully. Handle scrap correctly. Always keep spare Xrings in stock. Step 5 To remove the sensor unit untighten screw and pull out the sensor unit. TD

34 8 Maintenance Study the instructions carefully. Handle scrap correctly. Always keep spare Xrings in stock. 8.2 Assembly of ThinkTop Step Place sensor unit in base and tighten screw (torque: Nm). TD Step 2. Replace the black Xring. 2. Assemble base with adapter by turning adapter slightly anticlockwise and tighten the four screws (.9 Nm). CAUTION! DoNOTtwisttheXringinthegroove! The Xring is not square; The highest (h) part must be placed as fig. Note: Turn banjo connection! TD Step 3. Replace solenoid valves (up to three) with new ones. 2. Tighten screws (0.2 Nm). TD Step 4. Replace the grey Xring. 2. Replace cover of ThinkTop and tighten the four screws (0.6 Nm). TD

35 8 Maintenance Study the instructions carefully. Handle scrap correctly. Always keep spare Xrings in stock. Step 5. Replace the black Xring. 2. Mount ThinkTop on actuator

36 8 Maintenance Study the instructions carefully. Handle scrap correctly. Always keep spare Xrings in stock. 8.3 Dismantling and assembly of Series 700 valves Step. Remove the cover by loosening the four cover screws. 2. Separate the adapter from the base by loosening the three recess screws on top of the base. Installation on air actuators: TD Step 2. Fit air fittings on actuator. 2. Position packing retainer in recess on actuator top. 3. Fit counter nut and indicator (magnet) on actuator rod. Engage approx. ¼ thread. Tighten counter nut and indicator with two wrenches. Step 3. Place the two Orings in the grooves in the bottom of the adapter. Then place the adapter on the actuator top. The small Oring must be positioned over the air hole on the actuator. 2. Fasten the adapter with the four 5/6 Allen screws. Step 4. Mount the base on the adapter in the position needed (can be rotated 20 in both directions). Note that one of the screw towers on the adapter has a guide recess (see * on drawing). 2. Remove xrings (9) (grey) and (6) (black). 3. Replace with new ones. CAUTION! DoNOTtwisttheXringinthegroove! TheXringis notsquare;thehighest(h)partmustbeplacedasfig. TD

37 9 PartlistandServiceKits The drawings show ThinkTop Devicenet 25 VDC. The items refer to the parts lists in the following sections 9. Drawings for ThinkTop DeviceNet 25 VDC W H 7.6 mm 8 ø37 mm TD Note! This is the basic design. The clerance should be approximately: W225 x H250 W225 x H320 W225 x H300 (Unique SSV NC, SMPSC/ BV/TO, Unique Mixproof, MH, SBV) (Unique SSV NO) (LKLAT) 6b 6a TD

38 9 PartlistandServiceKits The drawings show ThinkTop Devicenet 25 VDC. The items refer to the parts lists in the following sections 9.2 ThinkTop DeviceNet 25 VDC 6b 6a 20 38

39 9 PartlistandServiceKits The drawings show ThinkTop Devicenet 25 VDC. The items refer to the parts lists in the following sections Parts list Pos. Qty Denomination Shell 3 Screw 4 Washer 5 Sensor board 6a Solenoid valve (3/2) 6b Solenoid valve (3/2) or 5/2) 7 PT screw 8 Base 9 Special Xring, grey 0 Air fittings Blowoff valve 2 Thread plug, PG7, ø3 ø6,5 mm 3 Cable gland, PG ø4 ø0 mm 4 Gore Vent. mambrane 5 Adapter 6 Special Xring, black 7 Oring 8 Allen screw 9 Special Xring 20 indication pin Service kits Denomination Intern number a Sensor unit DeviceNet 25 VDC a Solenoid valve 3/2, 8 VDC a Solenoid valve 5/2, 8 VDC a Indication pin a Special indication pin, SRCLS a Special indication pin, SSVLS a Air fitting, ø6 mm a Air fitting, / a Gore vent a Xring,pos a Xring, pos a Xring, pos

40 9 PartlistandServiceKits The drawings show ThinkTop Series 700 Valves The items refer to the parts lists in the following sections 9.3 Drawings for ThinkTop Series 700 Valves W H 7.6 mm ø37 mm TD Note! This is the basic design. The clerance should be approximately: W225 x H250 W225 x H320 W225 x H300 (Unique SSV NC, SMPSC/ BV/TO, Unique Mixproof, MH, SBV) (Unique SSV NO) (LKLAT) 6b 6a TD

41 9 PartlistandServiceKits The drawings show ThinkTop Series 700 Valves The items refer to the parts lists in the following sections 9.4 ThinkTop Series 700 Valves 6b 6a 2 4

42 9 PartlistandServiceKits The drawings show ThinkTop Series 700 Valves The items refer to the parts lists in the following sections Parts list Pos. Qty Denomination Shell 3 Screw 4 Washer 5 Sensor board 6a Solenoid valve (3/2) 6b Solenoid valve (3/2 or 5/2) 7 PT screw 8 Base 9 Special Xring, grey 0 Air fittings Blowoff valve 2 Thread plug, PG7 3 Cablegland,PG40mm 4 Pressure control valve 5 Adapter 6 Special Xring, black 7 Oring 8 Screw 9 Retainer 20 Oring 2 Oring 22 Indicator pin 23 Nut Service kits Denomination /4 Air connec. a Sensor unit DeviceNet 25 VDC a Solenoid valve 3/2, 8 VDC a Solenopid valve 5/2, 8 VDC a Indication pin a Air fitting, / a Gore vent a Xring, pos a Xring, pos

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